Battery Cell Thermal Runaway Monitoring with Cell-Level Prediction
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Solution Overview
Problem
Existing battery cell thermal run-away monitoring systems fail to identify which cell is overheating and are triggered too late, leading to corrosion, cross-contamination, and eventual system failure, with no early warning for potential thermal run-away events.
Innovation Solution
A system that monitors battery cell voltage and electrolyte consumption, using a historical database to predict thermal run-away by comparing real-time data with historical data from similar cells, allowing for early identification and replacement of potentially failing cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature monitoring is used to detect thermal run-away, then thermal run-away can be detected, but it cannot identify which specific cell is overheating and is triggered too late to prevent damage
Solution Approach 1:
The patent divides the battery system into individual cell-level monitoring units, with each cell having its own orifice and vacuum system for independent monitoring. This segmentation enables precise identification of which specific cell is experiencing thermal run-away while allowing independent response to each cell's condition.
2Reliability
If vacuum contact with electrolyte is used to monitor thermal run-away, then early detection is possible, but corrosive electrolyte contaminates the vacuum system causing false readings and eventual failure
Solution Approach 1:
The patent introduces a physical barrier (membrane or baffle) that acts as an intermediary between the vacuum system and the corrosive electrolyte. This barrier allows the vacuum to interact with indicators of thermal run-away (such as gas evolution or pressure changes) without direct contact between the vacuum components and the corrosive potassium hydroxide electrolyte, preventing contamination and maintaining system reliability.
3Reliability
If vacuum system is used for monitoring, then early thermal run-away detection is achieved, but the system degrades over time due to corrosion and cross-contamination
Solution Approach 1:
The patent extracts the harmful corrosive electrolyte from the vacuum system by using a physical barrier that prevents direct contact. The vacuum system monitors thermal run-away indicators without being exposed to the corrosive medium, thereby eliminating the source of corrosion and extending system lifespan.
Solution Approach 2:
The patent applies preliminary protective measures by installing corrosion-resistant materials and physical barriers before any corrosive damage can occur. This preventive approach protects the vacuum system components from electrolyte corrosion from the outset, maintaining system reliability throughout the intended operational life.
Data Source
AI summary
Thermal run-away monitoring of battery cells during charging is described. Thermal run-away monitoring of a battery cell includes charging the battery cell; measuring concurrently a state of charge of the battery cell, and at least one of voltage and electrolyte consumption while charging the battery cell; recording a set of data for the battery cell, each member of the set of data comprising the state of charge of the battery cell, and at least one of voltage and electrolyte consumption; comparing the set of data for the battery cell to a historical database of measurements from other battery cells characteristic of a type associated with the battery cell; and predicting a probability of thermal run-away of the battery cell based on comparison of set of data for the battery cell to the historical database of measurements from other battery cells characteristic of the type associated with the battery cell.